abs_mark_60

01-285

Electrical check of Mark 60 Special tools and equipment

VAG 1598/36 Adapter

VAG 1594 A Adapter set

VAG 1526 A Hand multimeter

VAG 1921 Pliers

VAG 1598 A Test box

Стр. 1 из 42Electrical check of Mark 60

23.09.2004http://127.0.0.1:8080/vw/servlet/Display?action=Goto&target=_top&type=repair&id=VW.A4.SU02.01.9&hit=35

http://127.0.0.1:8080/vw/servlet/Display?action=Goto&target=_top&type=repair&id=VW.A4.SU02.01.9&hit=35

01-286

The test steps from page Page 01-294 apply only to vehicles with ABS /EDL/ASR/ESP

For vehicles on which the On Board Diagnostic (OBD) does not give any indication of the source of the malfunction. Work through the complete electrical check.

For vehicles on which the OBD provides a direct indication of the source of the malfunction. Only carry out the test steps recommended in the DTC table (directed entry).

An overview of all the test steps in the electrical check can be found on Page Page 01-294 .




01-287

Test prerequisites

Switch ignition and electrical consumers off before commencing the check (headlights, lighting, fans ...).

Fuses must be OK (remove fuses from fuse holder to check).

Electrical Wiring Diagrams, Troubleshooting & Component Locationsbinder

- Pull fuse holder out of cable channel.

- Release ABS Control Module (w/EDL) -J104- connector -arrow 1- and pull off -arrow 2-.




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The specified values are matched to the V.A.G 1526 and are not necessarily applicable for other test modules.

- Connect test box V.A.G 1598/36 -1- to multi-pin connector of ABS control module (w/EDL) -J104- -2-.




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Multi-pin connector with contact assignments

Note:

All contacts not listed are currently not assigned and must never be connected to other components!

Contact assignment of connectors for voltage supply and self-diagnosis with the V.A.G 1551 scan tool

Contact 4 = Ground (terminal 31)

Contact 16

= Positive (terminal 30)

Contact 7 = K wire to contact 2 of multi-pin connector T47 of ABS control module (w/EDL) -J104-

Contact assignment of connector T47 wiring harness/ ABS control module (w/EDL) -J104-




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Contact Wiring connection to component ...

1 Voltage supply from battery +

2 Connector T16/7, K wire

3 Longitudinal acceleration sensor -G251- sensor wire(4MOTION vehicles only)

4 Voltage supply from ignition/starter switch

5 Longitudinal acceleration sensor -G251- Ground(4MOTION vehicles only)

6 Sensor for transverse acceleration -G200-

7 Longitudinal acceleration sensor -G251- voltage supply(4MOTION vehicles only)

8 Vehicles with navigation system only

9 Coding bridge to contact 12 (vehicles with ABS /EDL/ASR/ESP 4MOTION only)

10 Vehicles with navigation system only

11 Data bus wire Wiring diagrams

12

Coding bridge to contact 9 (vehicles with ABS /EDL/ASR/ESP 4MOTION only)

Coding bridge to contact 38 (vehicles with ABS /EDL/ASR/ESP front wheel drive only)




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13 ASR/ESP button -E256-

14 Coding bridge to contact 38 (vehicles with ABS and ABS /EDL/ASR front wheel drive only)

15 Data bus wire Wiring diagrams

16 Ground point on left-hand longitudinal member

17 Vacant

18 Sender 1 for brake booster -G201- voltage supply

19 Sender 1 for brake booster -G201- signal wire

20 Sender 1 for brake booster -G201- ground wire

21 Vacant

22 Vacant

23 Vacant

24 Ground wire for sensor for transverse acceleration -G200- and sender for rotation rate -G202-

25 Vacant

26 Voltage supply for sensor for transverse acceleration -G200- and sender for rotation rate -G202-




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27 Vacant

28 Vacant

29 Vacant

30 Vacant

31 Vacant

32 Voltage supply from battery +

33 Right front ABS wheel speed sensor -G45-

34 Right front ABS wheel speed sensor -G45-

35 Vacant

36 Left rear ABS wheel speed sensor -G46-

37 Left rear ABS wheel speed sensor -G46-

38

Coding bridge to contact 12 (vehicles with ABS /EDL/ASR/ESP front wheel drive only)

Coding bridge to contact 14 (vehicles with ABS and ABS /EDL/ASR front wheel drive only)




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39 Vacant

40 Sender for rotation rate -G202- signal wire

41 Brake light switch -F-

42 Right rear ABS wheel speed sensor -G44-

43 Right rear ABS wheel speed sensor -G44-

44 Vacant

45 Left front ABS wheel speed sensor -G47-

46 Left front ABS wheel speed sensor -G47-

47 Ground point on left-hand longitudinal member




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Test step overview

Component to be tested

Voltage supply for ABS hydraulic pump -V64- to ABS control module (w/EDL) -J104- - Perform test step 1

Voltage supply for valves in ABS hydraulic unit -N55- to ABS control module (w/EDL) -J104- - Perform test step 2

Voltage supply (ignition/starter switch) to ABS control module (w/EDL) -J104- - Perform test step 3

Function of brake light switch -F- - Perform test step 4

Resistance of right front ABS wheel speed sensor -G45- - Perform test step 5

Resistance of left front ABS wheel speed sensor -G47- - Perform test step 6

Resistance of right rear ABS wheel speed sensor -G44- - Perform test step 7

Resistance of left rear ABS wheel speed sensor -G46- - Perform test step 8

Voltage signal of right front ABS wheel speed sensor -G45- - Perform test step 9

Voltage signal of left front ABS wheel speed sensor -G47- - Perform test step 10

Voltage signal of right rear ABS wheel speed sensor -G44- - Perform test step 11




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Component to be tested

Voltage signal of left rear ABS wheel speed sensor -G46- - Perform test step 12

Warning lamp function for ABS warning light -K47- - Perform test step 13

Warning lamp function for warning light for brake system -K118- - Perform test step 14

Warning lamp function for ESP control lamp -K155- - Perform test step 15

Function of ASR/ESP button -E256- - Perform test step 16

Activation of steering angle sensor -G85- - Perform test step 17

Activation of sensor for transverse acceleration -G200-

Activation of sender for rotation rate -G202-

- Perform test step 18

Activation of sender 1 for brake booster -G201- - Perform test step 19

Check of data bus wiring - Perform test step 20

Voltage supply for V.A.G 1551, connector T16 - Perform test step 21

Resistance of K wire for self-diagnosis, connector T16 - Perform test step 22

Coding bridge - Perform test step 23




01-296

Test table (test steps 1 - 16)

Test steps 17 - 23 see page Page 01-310

Notes on test table

The socket designations of adapter V.A.G 1598/33 are identical to the ABS control module (w/EDL) -J104- contact designations in wiring diagram.

Electrical Wiring Diagrams, Troubleshooting & Component Locations binder

If the readings obtained deviate from the specifications, carry out repair measure in the right-hand part of the table.


Continuity checks with adapter set V.A.G 1594 A (bridging).

If the measured figures only deviate slightly from the specifications, clean sockets and plugs of the testers and adapter cables (with contact spray G 000 700 04 ) and repeat check. Before replacing components, check wiring and connections and also, particularly for specifications of less than 10 , repeat resistance check on the component.




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Switch to measuring range:

Voltage measurement (20 V =)

Test step

V.A.G 1598 sockets

Item tested Test conditions

- Additional operations

Specification Measures for deviations from specification

1 1 + 47 Voltage supply for ABS hydraulic pump -V64- to ABS Control Module (w/EDL) -J104-

Ignition switched off

10.0 - 14.5 V


- Check wiring using wiring diagram

2 32 + 16 Voltage supply for the valves in ABS hydraulic unit -N55- to ABS Control Module (w/EDL) -

J104-


10.0 - 14.5 V






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Test step

V.A.G 1598 sockets




3 4 + 47 Voltage supply (ignition/starter switch) to ABS Control Module (w/EDL) -J104-

Ignition switched on

10.0 - 14.5 V



4 47 + 41 Function of brake light switch -F- Ignition

switched off

Brake pedal not depressed

0.0 - 0.5 V

- Check brake light switch -F- and read measured value block Page 01-237 , Display group number 003

- Depress brake pedal

Approx. battery voltage

Repair Manual, Brake System, Repair Group 46; Brake pedal - Assembly overview; Adjusting brake light switch

- Adjusting brake light switch









01-299


Resistance measurement (2 k )

Test step

V.A.G 1598 sockets




5 33 + 34 Resistance of right front ABS wheel speed

sensor -G45-


1.0...1.3 k


- Wiggle wiring during test


If no malfunction can be located in the wiring:

- Replace right front ABS wheel speed sensor -G45-

Repair Manual, Brake System, Repair Group 45; Removing and installing parts of ABS system on front and rear axles




01-300



Test step

V.A.G 1598 sockets




6 45 + 46 Resistance of left front ABS wheel speed

sensor -G47-


1.0...1.3 k





- Replace left front ABS wheel speed sensor -G47-





01-301



Test step

V.A.G 1598 sockets




7 42 + 43 Resistance of right rear ABS wheel speed

sensor -G44-


1.0...1.3 k




If no malfunciton can be located in the wiring:

- Replace right rear ABS wheel speed sensor -G44-





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Test step

V.A.G 1598 sockets




8 37 + 36 Resistance of left rear ABS wheel speed

sensor -G46-


1.0...1.3 k





- Replace left rear ABS wheel speed sensor -G46-





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Voltage measurement (2 V )

Test step

V.A.G 1598

sockets




9 33 + 34 Right front ABS wheel speed sensor -G45- voltage signal

Vehicle raised - Check installation of right front ABS wheel speed sensor -G45- and rotor.


- Rotate front right wheel at approx. 1 rev./sec.

Min. 65 mV alternating voltage

- Check whether right front ABS wheel speed sensor -G45- has been interchanged and read measured value block Page 01-237 , Display group number 001

10 45 + 46 Left front ABS wheel speed sensor -G47- voltage signal

Vehicle raised - Check installation of left front ABS wheel speed sensor -G47- and rotor.


- Rotate front left wheel at approx. 1


- Check whether left front ABS wheel speed sensor -G47- has been interchanged




rev./sec. and read measured value block Page 01-237 , display group number 001




01-304


Voltage measurement (2 V )

Test step

V.A.G 1598

sockets




11 42 + 43 Right rear ABS wheel speed sensor -G44- voltage signal

Vehicle raised - Check installation of right rear ABS wheel speed sensor -G44- and rotor.


- Rotate rear right wheel at approx. 1 rev./sec.


- Check whether right rear ABS wheel speed sensor -G44- has been interchanged and read measured value block Page 01-237 , Display group number 001

12 37 + 36 Left rear ABS wheel speed sensor -G46- voltage signal

Vehicle raised - Check installation of left rear ABS wheel speed sensor -G46- and rotor.


- Rotate rear left wheel at approx. 1


- Check whether left rear ABS wheel speed sensor -G46- has been interchanged




rev./sec. and read measured value block Page 01-237 , Display group number 001




01-305

Functional check: ABS warning light -K47-

Test step

V.A.G 1598 sockets




13 - Function of ABS warning

light -K47-


- Switch on ignition

The ABS warning light -K47- lights up for approx. 2 seconds and goes out again



- Malfunction in instrument cluster

Repair Manual, Body Interior,Repair Group 70; instrument panel




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Functional check: Warning light for brake system -K118-

Test step

V.A.G 1598 sockets




14 - Function of warning light for brake system -K118-

Parking brake not applied

Brake fluid level OK


Warning light for brake system -K118- does not light up

- Apply parking brake

Warning light for brake system -K118- lights up








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Functional check: ESP Control Lamp -K155-

Test step

V.A.G 1598 sockets




15 - Function of ESP control lamp -K155-


- Switch ignition on

ESP control lamp -K155- lights up for 2 seconds and goes out again








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Functional check: warning lamp for ASR/ESP button -E256-

Test step

V.A.G 1598 sockets




16 - Function of ASR/ESP button -E256-


The function of the ESP Control Lamp -K155- was checked in test step 15.

ESP control lamp -K155- lights up for 2 seconds and goes out again

- Operate ASR/ESP button -E256-

ESP control lamp -K155- lights up

- Operate ASR/ESP button -E256- again

ESP control lamp -K155- goes out

Test step 16: Continued on next page.




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Continuation of test step 16

Test step

V.A.G 1598 sockets






ASR/ESP button -E256- faulty

- Replace ASR/ESP button -E256-





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Test table (test steps 17 - 23)


Voltage measurement (20 V =) in test step 17, resistance measurement (200 )/(20 M ) in test step 17a

Test step

V.A.G 1598 sockets




17 - Voltage supply for steering angle sensor -G85-


- Disconnect connection from steering angle sensor -G85-

- Disconnect multi-pin connection T47 from ABS control module (w/EDL) -J104-

- Check wiring between contact T6a/4 and contact T6a/1 of steering angle sensor -G85-

10.0 - 14.5 V - Check wiring using wiring diagram






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Test step

V.A.G 1598 sockets




17 - Voltage supply for steering angle sensor -G85-

- Ignition switched on

- Check wiring between contact T6a/5 and connector contact T6a/1 of steering angle sensor -G85-

10.0 - 14.5 V



Test step 17a: On next page.




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Continuation of test step 17a


Resistance measurement (200 /20 M )

Test step

V.A.G 1598 sockets




17a - Wiring for steering angle sensor -G85-

Measuring range set to 200


- Connect test box V.A.G 1598/36

- Check wiring for open circuit between steering angle sensor -G85- and

ABS control module (w/EDL) -J104- multi-pin connector

Max. 1.5



Test step 17a: On next page.




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Continuation of test step 17a

Test step

V.A.G 1598 sockets




17a Wiring for steering angle sensor -G85 - Set measuring range to 20

M

- Remove fuse S9

- Check wiring for short circuit to positive or Ground






01-314



Test step

V.A.G 1598

sockets




18 -

Wiring for sensor for transverse acceleration -G200- and sender for rotation rate -G202-



- Connect test box VAG 1598/36

- Check wiring for open circuit between multi-pin connector of sensor for transverse acceleration -G200-, sender for rotation rate -G202- and multi-pin connector of ABS control module (w/EDL) -J104-:

Max. 1.5







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Test step

V.A.G 1598 sockets




- Set measuring range to 20 M

- Remove fuse S9







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Test step

V.A.G 1598

sockets




19 - Wiring for sender 1 for brake booster -G201-



- Disconnect connection from sender 1 for brake booster -G201-

- Disconnect multi-pin connection T47 from ABS control module (w/EDL) -J104-


- Check wiring for open circuit between sender 1 for brake booster -G201- multi-pin connector and ABS control module (w/EDL) -J104- multi-pin connector

Max. 1.5







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Test step

V.A.G 1598 sockets





- Remove fuse S9







01-318



Test step

V.A.G 1598 sockets




20 11 or 15 Data bus wiring Ignition switched off

Measuring set range to 200

- Disconnect multi-pin connection from a control module which is connected via data bus wiring:


- Check data bus wiring for open circuit Max. 1.5



Test step 20: Continued on next page




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Test step

V.A.G 1598 sockets





- Remove fuse S9







01-320



Test step

V.A.G 1598 sockets




21 - Voltage supply for V.A.G 1551, connector T161)


- Connect hand multimeter V.A.G 1526 to connector T161) using adapter set V.A.G 1594

10.0 -14.5 V



1) Diagnosis connector contact assignment Page 01-289




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Resistance measurement 200

Test step

V.A.G 1598

sockets




22 - Resistance of K wire for V.A.G 1551, connector T161)


- Disconnect multi-pin connector from ABS control module (w/EDL) -J104

Max. 1.5




- Connect hand multimeter V.A.G 1526 to contacts T16/71) and T47/2 of multi-pin connector of ABS control module (w/EDL) -J104- using cables from adapter set V.A.G 1594

1) Diagnosis connector contact assignment Page 01-289




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Resistance measurement (200 )

Test step

V.A.G 1598 sockets




23 14 + 38 Coding bridge for

ABS and

ABS /EDL/ASR

front wheel drive


0.0 -1.0

12 + 38 Coding bridge for

ABS /EDL/ASR/ESP front wheel drive

12 + 9 Coding bridge for

ABS /EDL/ASR/ESP 4MOTION


Electrical Wiring Diagrams,




Troubleshooting & Component Locations binder




Documents

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